This application is a continuation-in-part of U.S. patent application Ser. No. 08/457,680, filed on Jun. 1, 1995 now U.S. Pat. No. 5,578,112, and a national stage application of International Patent Application No. PCT/CA96/00358.
This invention relates to ionizers and more particularly to a modular and low power ionizer suitable for commercial and residential use.
BRIEF SUMMARY OF THE INVENTIONConventional ionizers or precipitators comprise large and very specialized devices. These devices are intended for large industrial applications, for example a cement factory, and have high power requirements. Due to their large power requirements, the ionizers include separate high voltage power supplies and tend to be very bulky and costly to manufacture and maintain. The devices are typically designed as stand-alone units which are coupled to existing ventilation or heating and cooling equipment. For these reasons, known devices are not well-suited for commercial applications, such as once buildings, or residential or consumer use. Published European Patent Application No. 90850276.8 discloses one such device according to the prior art.
In an office building, the air circulation system includes a filter bank which comprises a matrix of filter modules. Each filter module typically has a mechanical filter element which traps particulate matter in the air before the air is circulated. The filter elements need to be replaced on a regular basis thereby incurring both maintenance and replacement costs. There is also a cost associated with the disposal of the used filter elements. For medical facilities, the filter elements are treated as hazardous biological waste and the disposal costs are significant. Furthermore, the air circulation fans must have the capacity to push the "dirty air" through the filter elements. For a typical once building this means large electric motors with a high horsepower output to drive the circulation fans, which further increases the cost of a conventional air conditioning/heating installation.
There is also reason to believe that filter elements which have become contaminated may contribute to "sick building syndrome".
BRIEF SUMMARY OF THE INVENTIONAccordingly, there is a need for an ionizer which is suitable for commercial and residential use. It is an object of the present invention to provide a modular ionizer which may be integrated with an existing heating or cooling duct in the heating and cooling equipment (HVAC) of a building. It is another object of the present invention to provide an ionizer with an integrated high voltage generator which is operated from conventional AC power and features low power consumption. It is a further object of the present invention to provide an ionizer which produces negligible amounts of ozone as a by-product of the ionization process. It is yet a further object of the present invention to provide a modular ionizer which is arranged with other ionizer modules to form an ionizer bank or matrix suitable for use in larger installations such as those found in residential condominiums, office buildings, medical facilities, laboratories, food processing plants, electronic assembly (i.e. "clean-room") plants, and manufacturing and industrial plants.
In a first aspect, the present invention provides an apparatus for purifying gas flowing in a duct by establishing a radially directed ionic wind within the duct to sweep particulate solids directly onto one or more collector electrodes, said apparatus comprising: (a) an ionizing unit; (b) means for supporting said ionizing unit within the duct, said ionizing unit comprising, (i) a water-tight housing, (ii) a high voltage generator within the housing and having a high voltage output, (iii) an electrode support rod coupled to said high voltage output and extending from said housing coaxially within said duct, (iv) at least one group of ionizing electrodes mounted on said support rod and extending radially therefrom; and (c) means for connecting said high voltage generator to an external low voltage power supply.
In a second aspect, the present invention provides an air purifier for purifying air in an enclosed space and said enclosed space being provided with an AC power supply, said air purifier comprising: (a) an enclosure having at least one collecting electrode; (b) an ionizing unit; (c) means for supporting said ionizing unit inside said enclosure, said ionizing unit comprising, (i) a water-tight housing, (ii) a high voltage generator within said housing for generating a high voltage output, (iii) an electrode support rod coupled to said high voltage output and extending from said housing coaxially within said duct, (iv) at least one group of ionizing electrodes mounted on said support rod and extending radially therefrom for establishing a radially directed ionic wind within said enclosure to sweep particulate solids in the air directly onto said collector electrode; (d) means for connecting said high voltage generator to the external AC power supply; and (e) said enclosure including an air intake port and an air exhaust port.
In a third aspect, the present invention provides a high voltage multiplier stage comprising: (a) an input port for receiving an input voltage signal; (b) a body member having two side channels for mounting capacitors and a bottom channel for mounting diodes, and said capacitors and diodes being coupled to form a plurality of stages for said high voltage multiplier; (c) said bottom channel being disposed between said side channels; (d) said last stage providing an output port for said high voltage multiplier.
BRIEF DESCRIPTION OF THE DRAWINGSReference will now be made to the drawings which illustrate, by way of example, a preferred embodiment of the present invention, and in which:
FIG. 1 is a cross-sectional view of an ionizing apparatus according to the present invention;
FIG. 2 is a block diagram of circuitry of the apparatus of FIG. 1;
FIGS. 3(a) to 3(c) show the circuitry of FIG. 2 in schematic form;
FIG. 4(a) shows a bank of ionizers according to the invention;
FIG. 4(b) shows another arrangement for a bank of ionizers according to the invention;
FIG. 5 is a timing diagram showing the relationship between selected control signals generated in the circuit of FIG. 3;
FIGS. 6(a) and 6(b) show in schematic form a transformer according to the present invention; and
FIGS. 7(a) to 7(c) show in schematic form an embodiment for a high voltage multiplier according to the present invention, and wherein FIG. 7(a) is a top view of the high voltage multiplier, FIG. 7(b) is a side view, and FIG. 7(c) is an end view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTSReference is first made to FIG. 1 which shows anionizing apparatus 1 according to the present invention. The ionizingapparatus 1 comprises a tubular member orconduit 2 and anionizer 4. As shown, theionizer 4 is mounted coaxially inside thetubular member 2 by asupport bracket 6. Thetubular member 2 can comprise an existing duct connected to the heating and cooling equipment (HVAC) of a building. Alternatively, thetubular member 2 can comprise a separate member which provides a housing or enclosure and an ionization chamber for theionizer 4. Thesupport bracket 6 also provides a power feed for theionizer 4. The power feed comprises apower cable 8 coupled to amains supply module 10.
In FIG. 1, theionizer 1 is shown mounted horizontally in thetubular member 2. It will be appreciated that theionizer 1 may also be mounted vertically in a vertical tubular member for example.
It is a feature of the present invention that theionizer 4 is powered using conventional AC or "mains" power and thesupply module 10 is simply plugged into a wall socket. Themodule 10 includes a conventional 115 VAC transformer. Furthermore, the modular nature of thedevice 1 allows theionizer 4 to be integrated with the existing heating or cooling system of a building. For example, thetubular member 2 can comprise a heating duct connected to the furnace. Thebracket 6 attaches theionizer 4 to theduct 2 and power is provided by an electrical outlet. For larger applications, e.g. an once building, theionizers 4 are arranged in a bank ormatrix 3 as shown in FIG. 4(a). Thebank 3 comprises a plurality of modules orcells 3a, 3b, 3c, 3d. . . each having an ionizer 4 (as depicted for thefirst cell 3a). The bank ormatrix 3 ofionizers 4 can replace or augment the existing air filter bank (not shown). Theionizers 4 can also be "daisy chained" inside the air circulation duct as shown in FIG. 4(b). In FIG. 4(b), another column ofmodules 5a, 5b, 5c, 5d are located behind themodules 3a, 3b, 3c, 3d. This arrangement can increase the amount of particulate matter removed from the air.
Alternatively, thedevice 1 is manufactured as a stand-alone unit which is positioned in a room, for example in a residential home, and plugged into a wall socket. The stand-alone unit includes intake and exhaust ports and can also have a fan (not shown). It will be appreciated that such a stand-alone unit will need appropriate EMI shielding and safety features.
As shown in FIG. 1, theionizer 4 comprises a water-tight enclosure 12 which houses ahigh voltage circuit 14. One end of theenclosure 12 is sealed by analuminum lid 16 which also acts as a heat sink for thehigh voltage circuit 14. The heat sink capability of thelid 16 is augmented by the flow ofair 34 through theduct 2, however, the direction for theair flow 34 can be opposite to that shown in FIG. 1. Acap 18 is attached to the other end of theenclosure 12 and provides a water-tight seal. Attached to thecap 18 through a sealed (e.g. rubber gasket) opening 119 is anelectrical discharge rod 20. Thedischarge rod 20 is electrically coupled through acontact 121 to thecircuit 14 and receives the high voltage output generated by thecircuit 14. Theelectrical discharge rod 20 preferably includes two or more groups of ionizing electrodes with two groups ofelectrodes 22,24 being shown in FIG. 1. Each group of ionizingelectrodes 22,24 comprises fourwires 26a, 26b, 26c and 28a, 28b, 28c with the fourth wire not being shown. The distance between adjacent ionizing electrodes, i.e. 26a and 28a, is approximately 18 inches. Each group of ionizingelectrodes 22,24 can comprise more than four wires, but preferably there are at least four wires. In another embodiment, the ionizingelectrodes 22,24 may be replaced by a wire mesh having openings of approximately 0.5 inches square.
As shown in FIG. 1, there is also provided aring 30. Thering 30 is coupled to theduct 2 by abracket 32 as shown in FIG. 1. Alternatively, thering 30 is supported by an insulated bracket 32' (shown in broken outline) which is connected to therod 20 and thering 30 is held at the desired potential, e.g. ground, using an insulated wire 33. Thering 30 is made from a conductive material such as copper and provides a collector electrode for the second group of ionizingelectrodes 24. As shown in FIG. 1, theionizing electrodes 28a, 28b are shorter than the ionizingelectrodes 26a, 26b in thefirst group 22, and the combination of thering 30 andionizing electrodes 28a, 28b (and 28c, 28d) ionizes a portion of the airflow in theduct 2 which does not pass over the first group of ionizingelectrodes 22. Thering 30 is suitable for use with thehigh voltage circuit 14 for producing a 60 kV output.
In operation, thehigh voltage circuit 14 produces a high voltage output from about 60 kV to 135 kV at 150 Watts. (The transformer, i.e. triple core, arrangement shown in FIG. 6 is utilized for producing the 135 kV output.) The high voltage output energizes thedischarge rod 20 and the ionizing electrodes 26,28. A flow of "dirty" air (or gas) 34 is passed through the ionization chamber,e.g. duct 2, and the air molecules and particulate matter in theair flow 34 are ionized as they pass by the ionizing electrodes 26,28. (Thedirty air 34 will contain particulate solids, such as dust, smoke and the like.) An ionic wind 127 (shown using a broken line outline) is produced between the wires 26 forming the firstionizing electrode group 22 and the inside surface of theduct 2. The duct 2 (i.e. inside surface of the duct 2) provides a collector electrode for collecting particles which are picked up by the action of the ionic wind 127. The primary function of theduct 2 is to act as a "collector" electrode to collect the particulate solids which are swept by the ionic wind 127 created by theionizing electrodes 26a, 26b, 26c, 26d. (Theduct 2 can also act as a "Faraday" cage or shield.) Similarly, for the second group of ionizingelectrodes 24, an ionic wind 29 (shown using a broken line outline) is generated between the tips of theionizing electrodes 28a, 28b, 28c, 28d and thering 30. Theionic wind 129 is predominantly negative, and therefore thering 30 is grounded by theduct 2 or the insulated wire 33. Theionic wind 129 generated by the second group of ionizingelectrodes 24 is intended fordirty air 36 which flows inside of theionizing electrodes 26a, 26b, 26c, 26d, for example, due to the turbulence caused around theend cap 18. The resulting clean air flow 34' and 36' continues to pass through theduct 2.
It has been found that the efficacy of theionizer 4 increases with the arrangement of thering 30 and theionizing electrodes 28a, 28b, 28c, 28d. Preferably, the distance between tips of theionizing electrodes 26a, 26b, 26c, 26d (orelectrodes 28a, 28b, 28c, 28d) and the duct 2 (or ring 30) is in therange 10 to 15 cm. It will be appreciated that the distance is also dependent on the field strength produced by theionizer 4.
There may also be applications where is advantageous to replace thering 30 and electrodes 28 with electrodes (not shown) which extend approximately the same distance as the electrodes 26. For example, when generating a full 135 kV output thering 30 is not used.
As shown in FIG. 1, theionizing apparatus 1 can also include acontrol panel 38. Thecontrol panel 38 provides a user interface for set-up and maintenance. Thecontrol panel 38 includes an ON/OFF switch 40, a POWER OUTPUT indicator 42 and an output current meter 44. Optionally, thecontrol panel 38 may include a RESET switch 46.
For maintenance, a water jet is used to clean the particles which have accumulated on the inside surface of theduct 2 or on the surface of thering 30. Because theenclosure 12 is water-tight, thedevice 1 may be conveniently washed without removing theionizer 4 from inside theduct 2. Alternatively, the modular nature ofionizer 4 andsupport bracket 6 permit theionizer 4 to be removed and the inside surface of the duct 2 (or housing) scrubbed or washed without theionizer 4 in place.
As shown in FIG. 1, a feature of the present invention is the arrangement of thehigh voltage circuit 14 inside a water-tight enclosure 12 which is mounted coaxially in themember 2. This arrangement simplifies construction and installation of thedevice 1 in existing duct work, and also facilitates cleaning of thedevice 1. The modular nature of theionizer 4 also makes it suitable for forming a bank ormatrix 3 as shown in FIGS. 4(a) and 4(b). Another feature of the present invention is the capability to use conventional AC power to operate thedevice 1 which makes thedevice 1 attractive for wide-spread applications, e.g. commercial office buildings and private residential homes, in addition to industrial applications. This advantage is realized by thehigh voltage circuit 14 according to this aspect of the present invention.
Thehigh voltage circuit 14 is shown in block diagram form in FIG. 2. Thehigh voltage circuit 14 comprises apulse control module 50. Thepulse control module 50 is coupled to anoutput drive module 52. Theoutput drive module 52 comprises a "push-pull" circuit which drives the primary winding of ahigh voltage transformer 54. As will be described, thepulse control module 50 produces pulse signals for controlling the "push-pull" circuit in theoutput drive module 52. The output, i.e. secondary winding, of thehigh voltage transformer 54 is coupled to ahigh voltage multiplier 56. Thehigh voltage multiplier 56 increases the voltage in the secondary winding of thetransformer 54 to a suitable high voltage level at anoutput port 58. (Thehigh voltage multiplier 56 is described below with reference to FIG. 7) Thehigh voltage output 58 is coupled to the discharge rod 20 (FIG. 1) through an electrical contact terminal 121 (FIG. 1). Thehigh voltage transformer 54 together with thehigh voltage multiplier 56 generate the high voltage output (e.g. up to 135 kV) for energizing the ionizing electrodes 26,28 connected to the discharge rod 20 (FIG. 1).
According to another aspect of the present invention the high voltage transformer 54 (depicted in FIG. 6) and the high voltage multiplier 56 (depicted in FIG. 7) form a "tuned" circuit to operate thetransformer 54 in resonance to generate the high output voltage levels, i.e 135 kV.
Referring to FIG. 2, thehigh voltage circuit 14 includes anoscillator 60. Theoscillator 60 provides a reference trigger signal for thepulse control module 50. The output from theoscillator 60 is coupled to thepulse control module 50 through abuffer stage 62. Thebuffer stage 62 provides the drive for the reference trigger signal and prevents loading of the output from theoscillator 60.
Thehigh voltage circuit 14 also includes anoutput regulator 64 as shown in FIG. 2. Theoutput regulator 64 is coupled to thetransformer 54 and thepulse control module 50. Theoutput regulator 64 comprises a feedback circuit which controls thepulse control module 50 on the basis of the output of thehigh voltage transformer 54. As will be described in more detail below, theoutput regulator 64 is configured to regulate the output voltage or the output current. In current regulation mode, the output current is maintained at a predetermined value, e.g. 250 μA, and the voltage level is allowed to vary in a range, e.g. 60 kV to 135 kV. In voltage regulation mode, the output voltage level is maintained at a preselected value as set by the potentiometer 146 (FIG. 3(c)).
Thehigh voltage circuit 14 is powered by thepower supply module 70. Thepower supply module 70 comprises the mains supply module 10 (FIG. 1) which is connected to the mains supply through a conventional cable and plug. The mains supplymodule 10 provides a 140 VDC output atterminal 11 and a 20 VAC output atterminal 13. The mains supplymodule 10 is shown in FIG. 3(c) and comprises anAC line transformer 15. The primary winding of theAC line transformer 15 is coupled to the mains supply cable and includes awired fuse 17 and the ON/OFF switch 40. As shown the terminal 11 for 140 VDC supply is coupled to the primary of thetransformer 15 through aresistor 400 and rectified by adiode 401. The secondary winding "steps down" the voltage to provide the 20 VAC supply at the terminal 13. The 140 VDC and 20VAC terminals 11, 13 and aterminal 9 for ground (GND) are coupled to thehigh voltage circuit 14 through acable 8.
Thecable 8 comprises a multi-conductor cable and additional conductors are included for connecting the circuit 14 (located in the enclosure 12) to the lamp 46 through terminal 19, to a voltage output level adjustpotentiometer 146 throughterminals 21, 23, to thecurrent meter 48 throughterminals 25, 27. Thecable 8 also includes a conductor which connects the lid 16 (FIG. 1) to a surge suppressor, i.e. ground spike,circuit 39 shown in FIG. 3(b) and comprising avaristor 41. Theconductor 29 is also coupled to the chassis for thecontrol panel 38.
Referring back to FIG. 2, thehigh voltage circuit 14 also includes anoverload protection module 66 and shortcircuit protection module 77. Theoverload protection module 66 has an input coupled to thehigh voltage multiplier 56, an input coupled to the shortcircuit protection module 77, an output coupled to thebuffer stage 62, and another output coupled to theoutput regulator 64. The input from thehigh voltage multiplier 56 preferably includes afilter network 87 which is described in more detail below.
If the output current of thehigh voltage circuit 14 exceeds a predetermined amount, theoverload protection circuit 66 is triggered to disable the pulse control module 50 (through thebuffer stage 62 input) and thereby theoutput drive module 52.
Theoverload protection module 66 is also triggered if a short circuit condition exists, for example, thehigh voltage transformer 54 malfunctions and draws a large current. If a short circuit condition occurs, the short circuit protection module triggers theoverload protection module 66. Theoverload protection module 66, in turn, shuts down thecircuit 14 by disabling thepulse control module 50 andoutput drive module 52.
Once triggered thepulse control module 50 remains disabled until theoverload protection module 66 is reset. The high voltage circuit includes areset module 68 for resetting theoverload protection module 66. Thereset module 68 automatically generates a reset signal after a predetermined time. Thereset module 68 can also be activated by manually depressing a reset switch (not shown) located on thecontrol panel 38. If theoverload protection module 66 is triggered by theshort circuit module 77, then preferably thecircuit 14 is enabled only manually so as to provide an opportunity to investigate the cause of the short circuit.
Theoscillator 60 also provides a timing reference signal for thereset module 68 in order to provide for the automatic reset feature. This feature is described in more detail below.
Reference is next made to FIGS. 3(a) to 3(c) which show thehigh voltage circuit 14 in more detail. The values for the components shown in FIG. 3 are listed in the Table below. As shown in FIG. 3(a),terminal 72 connects toterminal 11 for the 140 VDC input and terminal 74 connects toterminal 13 for the 20 VAC input. Theground terminal 9 is connected toterminal 76. The 140 VDC input is "smoothed" by acapacitor 402 andresistor 403. The 20 VAC input is rectified by adiode 404 and smoothed by acapacitor 405. The rectified 20 VAC provides the input to avoltage regulator 78 onterminal 80. Thevoltage regulator 78 is shown in FIG. 3(b) and comprises a conventional device such as the LM7812 from National Semiconductor. Theregulator 78 provides a +12 Volt rail 82 and includes a capacitor 406 for smoothing the +12 Volt output. The +12 Volt rail 82 provides the supply voltage for components comprising thehigh voltage circuit 14. Thehigh voltage circuit 14 also includes thesurge suppressor 39. The function of thesurge suppressor 39 is protect thecircuit 14 by shunting voltage spikes to ground. As shown thesurge suppressor 39 comprises avaristor 41 with one terminal connected to ground and the other terminal connected to theconductor 29 which is also connected to the chassis.
Referring back to FIG. 3(a), the 140 VDC feed energizes the primary winding of thehigh voltage transformer 54. The primary winding of thetransformer 54 has a centre-tap 84 which receives the 140 VDC. As shown in FIG. 3(a), the 140 VDC is coupled to the centre-tap 84 through a branch of the shortcircuit protection module 77. (The terminals of the primary winding are connected to theoutput drive module 52 and operated in a "push-pull" manner as described below.)
The shortcircuit protection module 77 comprises aninductor 86 connected in series between the 140VDC input 72 and the centre-tap 84 of thehigh voltage transformer 54. The branch also includes awired fuse 88 and acapacitor 407 in parallel with theinductor 86. Theinductor 86 is magnetically coupled to areed switch 90. One terminal of thereed switch 90 is coupled to avoltage input 92. The other terminal of theswitch 90 forms an output 94 which is coupled to an input of theoverload protection module 66. As shown in FIG. 3(a), the output terminal of thereed switch 90 includesresistors 408, 409 andcapacitor 410 for conditioning the output signal at terminal 94.
If a short circuit condition arises, thehigh voltage transformer 54 will draw current which produces a magnetic field in theinductor 86. The magnetic field, in turn, "trips" thereed switch 90 which produces a pulse at terminal 94 for theoverload protection module 66 at the terminal 94. The resulting pulse triggers theoverload protection module 66 and causes thepulse control module 50 to become disabled as will be described in more detail below.
In a variation of the shortcircuit protection module 77 theReed switch 90 andinductor 86 are replaced by a photodiode and phototransistor arrangement as shown in FIG. 3(a) and denoted byreference 79. The implementation of thecircuit 79 as shown in FIG. 3(a) is within the knowledge of one skilled in the art.
Reference is next made to FIG. 3(b). Theoscillator 60 is implemented using aprogrammable timer chip 96, such as the MC14541 available from Motorola Corporation. Thetimer chip 96 is configurable to provide an output signal 98 onpin 1 between 16 kHz to 22 kHz. The appropriate selection of the values forresistors 411, 412 andcapacitors 413, 414 coupled topins 2 and 3 of thetimer chip 96 and the voltage level connected to pin 12 is within the understanding of those skilled in the art. (Exemplary values for the resistors and capacitors are provided in the Table below for a 19 kHz signal 98.) Thetimer chip 96 also includes a 16-stage binary counter which provides a timing signal onoutput pin 8 for use by thereset module 68.
The 19 kHz signal 98 provides the reference signal for thepulse control module 50 and is buffered by thebuffer stage 62. As shown in FIG. 3(b), thebuffer stage 62 is implemented using a single package chip containing sixinverters 100 to 110, such as the MC4049 available from Motorola Corporation. The individual inverters are cascaded in pairs 100,102 and 104,106 and 108,110 to produce respective non-inverting buffers. The buffer stage produces two buffered output reference signals 112, 114 which are 180° out of phase. The bufferedoutput signals 112, 114 provide the reference inputs to thepulse control module 50. As shown in FIG. 3(b), theinverters 104, 108 are also coupled to theoverload protection module 66 throughrespective diodes 415, 416 andresistors 417, 418. This aspect is described in further detail below.
Thepulse control module 50 and theoutput drive module 52 comprise a "push-pull" arrangement which drives thehigh voltage transformer 54. The push-pull arrangement produces a more efficient power output from thehigh voltage transformer 54.
As shown in FIG. 3(a), theoutput drive module 52 comprises a pair ofpower transistors 116, 118. The outputs, i.e. drain and source, of thetransistors 116, 118 are coupled to the primary winding of thehigh voltage transformer 54. The control input, e.g. gate, of thetransistors 116, 118 are coupled torespective outputs 120, 122 of thepulse control module 50. Thepulse control module 50 produces pulse trains 124, 126 which switch therespective transistors 116, 118 ON and OFF, thereby controlling the current flowing in the primary winding of thetransformer 54. As described above, thehigh voltage transformer 54 has the centre-tap 84 on the primary winding which is connected to the 140 VDC supply. The current flowing in the primary winding induces a voltage in the secondary winding of thetransformer 54. The voltage induced in the secondary winding is multiplied by thehigh voltage multiplier 56 to generate a high voltage at theoutput 58.
Thepulse control module 50 comprises a pair ofmonostable multivibrators 128, 130 which are implemented using first and second LM555type timer chips 132 and 134. As will be understood by those skilled in the art each of the 555timer chips 132, 134 has a network of resistors and capacitors which configure the timer chips 132, 134 as monostable multivibrators (i.e. pulse generators). (Exemplary values for theresistors 419 to 425 andcapacitors 426, 427 are provided in the Table below.) The reference signal 112 provides the "trigger" signal for the first monostable vibrator or pulse generator 128, and thereference signal 114 provides the "trigger" signal for thesecond monostable 130. In response to the reference signal 112, the first pulse generator 128 generates thepulse signal output 124 which drives the gate of thepower transistor 116. Similarly, thesecond pulse generator 130 produces thepulse signal 126 which drives the gate of thesecond power transistor 118. The duty cycle of eachpulse signal 124, 126 is determined by a resistor/capacitor network connected to the THRESHOLD and DISCHARGE inputs of the respective 555timer chip 132, 134 as will be within the understanding of those skilled in the art. In the preferred embodiment, the duty cycle is approximately 25%. To protect thetransistors 116, 118 the outputs of thepulse generators 128, 130 includeresistors 428, 429 as shown in FIG. 3(b).
Preferably, thetransistors 116, 118 comprise insulated-gate bipolar power transistors of the type available from International Rectifier, e.g. model no. IRGPC50FD2 is suitable.
The relationship between the pulse signals 124, 126 is shown in FIG. 5. There is a phase shift or time lag between the pulse signals 124, 126 which produces the "push-pull" action for thepower transistors 116, 118, i.e. when thefirst transistor 116 is ON, thesecond transistor 118 is OFF. When thehigh voltage circuit 14 is set to full power output (e.g. using potentiometer 146--FIG. 3(c)), each pulse has a width of approximately 15 microseconds. At minimum power output, the pulse width for the pulse signals 124, 126 is approximately in micro-second range.
Referring back to FIG. 3(a), the primary winding of thehigh voltage transformer 54 includes the centre-tap 84 which is connected to the 140 VDC feed from thepower supply module 70. In response to the pulse control signals 124, 126, the current is first "pushed" and then "pulled" through the primary winding of thetransformer 54. For example, when thefirst transistor 116 is ON, thesecond transistor 118 is OFF, and current flows through thefirst transistor 116 and a voltage is induced in the secondary winding of thetransformer 54. Conversely, when thesecond transistor 118 is ON, thefirst transistor 116 is OFF, and current flows in the opposite direction through thesecond transistor 118 and the primary winding of thetransformer 54. The push-pull arrangement according to the present invention reduces the magnetization of the core of the high voltage transformer which would occur if the primary winding was excited in only one direction, e.g. CLASS A mode. Because the operation of thetransistors 116, 118 alternates the current direction in the primary winding, the magnetic field in the transformer core is allowed to collapse during the time lag between respective pulses in thesignals 124, 126 (FIG. 5). This allows thetransformer 54 to operate more efficiently. As shown in FIG. 3(a), aresistor 430 and acapacitor 431 is connected across the primary winding of thetransformer 54. Theresistor 430 and thecapacitor 431 help control transients which may arise in the primary winding as a result of the switching of thetransistors 116, 118.
Referring again to FIG. 3(a), each time one of thetransistors 116, 118 is switched on, a current flows in the primary winding and a voltage is induced in the secondary winding of thetransformer 54. The secondary winding of thetransformer 54 "steps-up" induced voltage and the induced voltage is increased up to 135 kV through the operation of thehigh voltage multiplier 56.
According to another aspect of the present invention, thehigh voltage transformer 54 comprises a multi-core arrangement as depicted in FIGS. 6(a) and 6(b). Thetransformer 54 comprises a primary winding 55, a secondary winding 57, and amultiple core 59. Themultiple core 59 comprises threeferrite cores 61,63,65. Eachferrite core 61,63,65 hasair gaps 67,69 to reduce hysteresis in the core. The primary winding 55 comprises 18 turns for each core 61,63,65, and the turns ratio for the secondary winding 57 is approximately 1/50. The secondary winding 57 is preferably vacuum sealed in epoxy resin. It will be appreciated that the multiple core arrangement depicted in FIG. 6 has the advantage of limiting the Eddy currents to each core 61,63,65.
According to this aspect of the invention, thetransformer 54 comprises atriple core arrangement 59 in order to generate a high voltage output on the secondary 57 without requiring a high turns ratio. By limiting the turns ratio, the size of thetransformer 54 is reduced.
The triple core arrangement for thetransformer 54 shown in FIG. 6 is suitable for a 150 Watt system. For a 100 Watt system, a two core arrangement, e.g. 61 and 63, is possible with the turns ratio for the secondary winding suitably modified. For a 50 Watt system, a single core arrangement is possible with the turns ratio suitably modified.
To further increase the output to 135 kV, thetransformer 54 is operated in resonance. Thetransformer 54 and thehigh voltage multiplier 56 comprise a "tuned" circuit. The higher frequency the more efficient thetransformer 54 and the higher the output, however, the limitation becomes the switching frequency of thetransistors 116, 118 in thepulse control module 50. For thetransistors 116, 118 being used utilized the switching frequency is selected in therange 16 kHz to 22 kHz. Theair gap 67,69 is approximately 0.004 inches and adjusted so that thetransformer 54 produces 7.5 kV peak output at resonance.
As shown in FIG. 3(a) the secondary winding is coupled to thehigh voltage multiplier 56. Thehigh voltage multiplier 56 comprises a series of cascaded stages. The multiplier comprises seven cascaded stages, three of which are shown and denoted byreferences 136, 138, 140. Each cascaded stage is formed from a series of capacitors and diodes. The capacitors and diodes are configured as a voltage multiplier as will be understood by those skilled in the art. (If theinsulated wire 23 is used with thering 30, the capacitance of thewire 23 is factored into the cascade stage.) The function of thehigh voltage multiplier 56 is to further increase or multiply the "step-up" voltage produced in the secondary winding of the transformer 54 (through the "push-pull" switching of the 140 VDC in the primary winding of the transformer 54).
In the present configuration, i.e. the tuned circuit comprising thetransformer 54 and thevoltage multiplier 56, the output is as high as 135 kV, and the capacitors are 680 picofarads and rated at 15 KV. The diodes are rated for 35 kV RMS at 2 milliamperes (mA). The output of thehigh voltage multiplier 54 is electrically coupled to thedischarge rod 20 by the electrical contact 21 (FIG. 1). The "tuned"high voltage multiplier 56 is shown in FIG. 7 and described below. With suitable modifications to thehigh voltage transformer 54 and the high voltage multiplier 56 (e.g. increasing the number of stages), an output voltage around 180 kV may be achieved.
Referring to FIG. 3(a), a third winding 142 on the core of thehigh voltage transformer 54 provides aninput 144 for theoutput regulator 64. The function of theoutput regulator 64 is to regulate or control the output voltage produced by thecircuit 14. Theregulator 64 is also configurable to regulate the output current. In voltage regulation mode, the output voltage level is held at a level as set through the potentiometer 146 (FIG. 3(c)). In current regulation mode, the current is maintained at a predetermined level, e.g. 250 μA and the voltage is allowed to vary between 60 kV to 135 kV, and will depend on the current needed to charge the particulate in theair 34.
The output voltage is regulated by controlling the duty cycle of thepulses 124, 126 (FIG. 3(b)) based on the desired output voltage level. The output voltage level is set by thepotentiometer 146 shown in FIG. 3(c), which is coupled to the winding 142. Thepotentiometer 146 is preferably located inside thecontrol panel 38 so as to be accessible only to a trained technician. The wiper of thepotentiometer 146 forms the terminal 23 and is coupled to a Zener diode 148 at terminal 155 in theregulator 64. The Zener diode 148 provides the input for theregulator 64. Theother terminal 21 of the adjust dial 42 is connected to the terminal 144 at the winding 142.
Referring to FIG. 3(b), theoutput regulator 64 comprises aNPN transistor 150 and a PNP transistor 152. The cathode of the Zener diode 148 is coupled to the collector of theNPN transistor 150 through aresistor 432 and the anode of the diode 148 is coupled to the base of theNPN transistor 150 through aresistor 433. The base of theNPN 150 is also coupled to signal ground through a diode 434. The collector of theNPN 150 is coupled to the base of the PNP transistor 152 through aresistor 435. The base of the PNP 152 is also coupled through a resistor 436 to theoutput 154 from theoverload protection module 66. The emitter of the PNP 152 is tied to 12 Volts through two diodes 437. The diodes 437 bias the PNP 152 so that the minimum pulse width is limited to 0.2 μs. The collector of the PNP transistor 152 provides the output for theregulator 64 and is coupled to thepulse control module 50 through a capacitor 438. Theresistor 435 and capacitor 438 produce a bias voltage for the resistor/capacitor networks for the 555timers 132, 138 and control the duty cycle of the respective pulse signals 124, 126.
In voltage regulation mode, the voltage induced in the winding 142 (FIG. 3(a)) is proportional to the output voltage at theoutput 58 of thecircuit 14. When the voltage in the winding 142 exceeds the threshold level (as set by thepotentiometer 146--FIG. 3(c)), the zener diode 148 will conduct causing theNPN transistor 150 to turn ON. This in turn causes the PNP transistor 152 to turn ON and the bias voltage on the capacitor 438 changes thereby causing the pulse width and the duty cycle of the pulse signals 124, 126 to decrease. By varying the duty cycle of thesignals 124, 126, the level at thehigh voltage output 58 and ionization is varied. In the present embodiment, the output voltage is regulated to 135 kV at 1.0 mA, or to 100 kV at 1.5 mA.
Referring to FIG. 3(b), when theoverload protection module 66 is triggered theoutput 154 is pulled LOW and the PNP transistor 152 is turned OFF. This effectively disables the 555timers 132, 134 as will be described in more detail below.
In another aspect, theoutput regulator 64 allows the output current level to be controlled. It has been found that current regulation is ideal for cleaning air which contains a lot of particulate matter, and the more particulate matter the easier it is to charge and maintain the charge. In other words, the more particulate matter the lower the current required once the particulate is charged. Voltage regulation, on the other hand, is preferable when the air is relatively clean, e.g. office spaces, because it takes more current to charge the particulate in current regulation mode.
To select current regulation, there is a terminal 151 which is connected to node 170 (i.e. the output of the filter network 87) and a switch orjumper 153. Thejumper 153 couples the terminal 151, i.e. output of thefilter 87 to the anode of the zener diode 148 at terminal 155. In current regulation mode theNPN transistor 150 is coupled to the output of thefilter network 87, and the current flowing controls theNPN transistor 150 which in turn controls the PNP transistor 152 and the bias voltage on the capacitor 438. For the component values shown in the Table below, the output current is regulated at 250 μA.
As shown in FIG. 2, thefilter network 87 couples the output signal from thehigh voltage multiplier 56 to theoverload protection module 66. The function of thefilter network 87 is to condition the output signal from thevoltage multiplier 56 in order to prevent false triggering of theprotection module 66.
Referring to FIG. 3(b), thefilter network 87 comprises abranch having resistors 445 to 448 andcapacitors 449 to 451 connected as shown. The other branch of thefilter network 87 comprisescapacitor 452. Thefilter 87 has aninput terminal 162 which is connected to the secondary winding of thehigh voltage transformer 54. The frequency characteristic of thefilter network 87 is configured according to the resonant frequency of thetransformer 54. The exemplary values for the resistors and capacitors provided in the Table are suitable for the 19 kHz switching frequency. For 16 kHz operation, a suitable value for theresistors 445 to 448 is 1.1 K, and for 20 kHz operation, a suitable value for theresistors 445 to 448 is 560 Ohms.
As shown in FIG. 3(a), theoutput 164 from thehigh voltage multiplier 56 includes anetwork 166 comprising avaristor 168, a blockingdiode 452,resistors 453 and 454, andcapacitors 455, 456 connected as shown. The function of thenetwork 166 is to "smooth" output signal tapped from thevoltage multiplier 56. Thevaristor 168 absorbs spikes in the output signal from themultiplier 56 by shunting them to ground before they can reach theoverload protection module 66.
Referring back to FIG. 3(b), at theinput terminal 162 to thefilter 87, the signal is split into the two branches. One branch shifts the phase of the signal forward, while the other branch shifts the phase of the signal back, so that when the signal is recombined atnode 170, i.e. the input to theoverload protection module 66, the ripple in the signal is effectively cancelled. In current regulation mode, the signal from thefilter network 87 provides the input to the zener diode 148 as described above.
Referring to FIG. 3(b), the signal from thefilter network 87 is input to theoverload protection module 66 atnode 170. Theoverload protection module 66 comprises first and second thyristors or silicon controlled rectifiers (SCR) 172 and 174. The first SCR 172 provides protection for overload voltage conditions. Thesecond SCR 174 provides protection for temperature overload conditions. The SCR 172 disables thecircuit 14 if a predetermined output current level is exceeded. Thesecond SCR 174, on the other hand, disables thecircuit 14 if a safe operating temperature is exceeded, for example 75° C. As shown in FIG. 3(b), eachSCR 172, 174 includes an input network denoted respectively by 173 and 174.
The gate of the first SCR 172 receives the output signal from the filter network 87 (i.e. node 170) through aresistor 457. The value of theresistor 457 is selected so that the SCR 172 is triggered at the appropriate output level. (As described, thefilter network 87 removes the ripples or spikes in the signal to prevent false triggering of the SCR 172.) The gate of the SCR 172 includes adiode 458 andcapacitor 459 which form aninput 176 for connecting to terminal 94, i.e. the output the shortcircuit protection module 67 shown in FIG. 3(a). The gate of the SCR 172 is also connected to signal ground through athermistor 178 and aresistor 460 as shown in FIG. 3(b). The function of thethermistor 178 is to compensate the SCR 172 when the unit becomes warm. As the temperature rises inside theenclosure 12, the SCR 172 will become more sensitive and susceptible to false triggering.
In operation, when the output current exceeds the predetermined threshold level, the SCR 172 is triggered and the output of the SCR 172 goes LOW. (As shown in FIG. 3(b), the output of the SCR 172 is tied to +12 Volts throughresistor 461.) When the output of the SCR 172 goes LOW, the pulse signals 112, 114 to the respectivemonostable vibrators 128, 130 are disabled, which, in turn, prevents thepower transistors 116, 118 (FIG. 3(a)) from switching. As shown in FIG. 3(b), the output of the SCR 172 is also coupled to the base of the PNP transistor 152 in theregulator 64. Triggering of the SCR 172 also causes the regulator input to the 555timers 132, 134 to be disabled. The monostable vibrators orpulse generators 128, 130 remain in the disabled state until the SCR 172 is reset by thereset module 68.
As shown in FIG. 3(b), thereset module 68 comprises atimer 180 and anoutput transistor 182. Thetimer 180 is configured to produce an output signal which turns on thetransistor 182 after a predetermined time. Theoutput transistor 182 is connected across the SCR 172. When turned on, the transistor 172 effectively "shorts-out" the SCR 172 and the SCR 172 is reset. (The SCR 172 resets below 0.7 Volts and the collector-emitter voltage for thetransistor 182 in saturation is 0.2 Volts.) Thetimer 180 is implemented using the MC14566 industrial time base generator chip available from Motorola Corporation. Thetimer chip 180 has aninput 184 which is connected to the output of the timer (oscillator)chip 96 for receiving atiming signal 186. Thetimer 180 is configured to produce an output signal for turning on thetransistor 182 approximately every 4 minutes (PIN 12 of theoscillator chip 96 is tied to +12 Volts) or approximately every 4 seconds (PIN 12 of theoscillator chip 96 tied to GROUND) as will be within the understanding of one skilled in the art. As shown in FIG. 3(b), the output of thetimer 180 is coupled to the base of thetransistor 182 throughresistor 462. Thetimer 180 itself is reset through the operation of thetransistor 182. As shown, thetimer 180 has areset input 188 which is coupled to the collector of thetransistor 182 through aresistor 463 and acapacitor 464.
Referring to FIG. 3(b), thesecond SCR 174 in conjunction with a thermistor 190 provides the over-heating protection for thehigh voltage circuit 14. The thermistor 190 is coupled to the gate of theSCR 174 through azener diode 192, aresistor 465, and anotherzener diode 194 as shown in FIG. 3(b). The output of theSCR 174 is tied to +12 Volts through resistor 466 and also to thebuffer inputs 104, 108 to themonostable vibrators 128, 130. When the operating temperature exceeds a predetermined threshold, e.g. 75° C., theSCR 174 is triggered and pulls the input to thebuffers 104, 108 to ground thereby disabling the monostable vibrators 128, 130 (i.e. pulse generators). Since a high temperature condition may indicative of a malfunction, as opposed to an overload condition, a blockingdiode 196 coupled to theSCR 174 prevents theSCR 174 from being automatically reset by thereset module 180. To reset theSCR 174 the unit must be powered down which is appropriately done by a technician who will also inspect the for a malfunction.
Theoverload protection module 66 also includesterminals 198, 200 for connecting to the current meter 48 (FIG. 3(c)). The terminal 198 is formed at the junction ofcapacitor 467 andresistor 468 which is connected to the output of thefilter network 87 atnode 170. The terminal 200 is formed at the junction ofresistor 469 and signal ground. The other terminal ofresistor 469 is connected to the gate of theSCR 174. The terminal 198 is connected toterminal 27 of themeter 48 andterminal 200 is connected to the "return" terminal 25 as shown in FIG. 3(c). Themeter 48 includes acalibration resistor 202.Terminal 25 of themeter 48 is connected to thepotentiometer 146 throughresistor 470 as shown in FIG. 3(c).
As shown in FIG. 3(a), the power output indicator 46 is also connected to the winding 142 through adrive circuit 158. The lamp 46 is connected to thedrive circuit 158 at terminal 19 (FIG. 3(a)). Thedrive circuit 158 for the lamp 46 comprises atransistor 160. The base of thetransistor 160 is coupled to the winding 142 throughresistor 439, capacitor 440 and rectifyingdiode 441. The collector of thetransistor 160 is coupled to terminal 19 throughdiode 442. Thedrive circuit 158 also includes anotherdiode 443 and resistor 444 which couple the terminal 19 to signal ground.
In operation, the lamp 46 will glow dimly when the unit is on. When a voltage is induced in the winding 142, a base current will flow causing thetransistor 160 to turn ON and the collector current causes the lamp 46 to glow brightly. If the output of theionizer 4 has been shorted, the continuous resetting of theoverload protection module 66 will cause the lamp 46 to flicker every 4 minutes (or 4 seconds).
Referring to FIG. 3(a), the anode of thediode 441 is also coupled to a terminal 220. The terminal 220 connects to the input terminal of acircuit 222 shown in FIG. 3(b). The circuit. 222 providesoutput terminal 224 and test point terminal 226. Thecircuit 222 processes the negative portion of the output at the coil 142. Thecircuit 222 comprises capacitors 471,472,diode 473, andresistor 474. Exemplary component values are provided in the Table below.
As described above, thehigh voltage multiplier 56 and thetransformer 54 can comprise a "tuned" circuit. Reference is next made to FIGS. 7(a) to 7(c) which show thehigh voltage multiplier 56 according to this aspect of the present invention. Thehigh voltage multiplier 56 comprises an enclosure denoted generally byreference 204. Theenclosure 204 comprises acompartment 206 for housing the cascaded stages 136, 138, 140 (FIG. 3(a)) of themultiplier 56 and atube 208 for connecting theoutput wire 58. The cascaded stages (e.g 136, 138, 140) are formed from diodes and capacitors denoted respectively by D and C. The input to themultiplier 56 is connected to the secondary winding of thehigh voltage transformer 54 through an AC wire and a ground wire. A principle function of thehigh voltage multiplier 56 is to lower the capacitance between the AC and ground in order to operate thetransformer 54 in resonance.
As shown in FIG. 7, thecompartment 206 hasrespective side channels 210, 212 for mounting the capacitors C and abottom channel 214 for mounting the diodes D. Thechannels 210, 212, 214 are preferably filled with an epoxy material. Theenclosure 204 includes one ormore channels 216 for receiving dielectric materials in order to change the capacitance and therefore the impedance and output voltage produced by thehigh voltage multiplier 56.
For a 135 kV output, thehigh voltage multiplier 56 comprises 9 stages, and the capacitors C are 680 pF and rated at 15 kV, and the diodes D are rated at 35 kV and 2 mA.
It will be appreciated that thehigh voltage circuit 14 according to the present invention provides an elegant and cost-effective solution to implementing theionizer 4. Thehigh voltage circuit 14 combined with the modular design of theionizer 4 provides a device which can easily be integrated with the existing duct work or arranged as an ionizer bank to replace known mechanical filter banks in an office building for example.
The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Therefore, the presently discussed embodiments are considered to be illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
______________________________________ TABLE FOR COMPONENT VALUES ______________________________________ Varistor 41 120 V Potentiometer 146 50K Zener Diode 148 15 V Transistor 150 4624 Transistor 152 4626 Transistor 160 U45 Varistor 168 20 V SCR 1 172 5061 SCR 2 174 5061 Thermistor 178 100K, 20° C. Transistor 182 4124 Thermistor 190 100K, 20° C. Zener Diode 192 7.8 V Zener Diode 194 7.5 V Diode 196 914 Resistor 400 1.5, 10 W Diode 401 8 A, 400 V Capacitor 402 680 μF, 200 V Resistor 403 100K, 1 W Diode 404 4007 Capacitor 405 1000 μF, 40 V Capacitor 406 2.2 μF Capacitor 407 2.2 μF Resistor 408 100K Resistor 409 220K Capacitor 410 1 nF Resistor 411 100K Resistor 412 220K Capacitor 413 180 pF Capacitor 414 50 pF Diode 415 914 Diode 416 914 Resistor 417 18K Resistor 418 18K Resistor 419 18K Resistor 420 18K Resistor 421 6.8K Resistor 422 1.8K Resistor 423 18K Resistor 424 18K Resistor 425 6.8K Capacitor 426 1 nF Capacitor 427 1 nF Resistor 428 27 Ohms Resistor 429 27 Ohms Resistor 430 5.6K Capacitor 431 150 pF Resistor 432 18K Resistor 433 820K Diode 434 914 Resistor 435 18K Resistor 436 47K Diodes 437 4126 Capacitor 438 0.1 μF Resistor 439 10K Capacitor 440 2.2 μF, 100 V Diode 441 4007 Diode 442 4007 Diode 443 4007 Resistor 444 100 Ohms, 1 W Resistor 445 680 (1.1K, 560 Ohms) Resistor 446 680 (1.1K, 560 Ohms) Resistor 447 680 (1.1K, 560 Ohms) Resistor 448 680 (1.1K, 560 Ohms) Capacitor 449 15 nF Capacitor 450 15 nF Capacitor 451 15 nF Capacitor 452 1 nF Resistor 453 18 Ohms Resistor 454 1K, 1 W Capacitor 455 0.1 μF Capacitor 456 2.2 μF, 100 V Resistor 457 220K Diode 458 914 Capacitor 459 1 nF Resistor 460 57K Resistor 461 1.5K Resistor 462 18K Resistor 463 1M Capacitor 464 47 pF Resistor 465 18K Resistor 466 18K Capacitor 467 2.2 μF Resistor 468 2.2K Resistor 469 220K Resistor 470 12K Capacitor 471 0.1 μF Capacitor 472 680 pF Diode 473 4007 Resistor 474 6.8K Resistor 475 5K Capacitor 476 2.2 μF ______________________________________